General Disclaimer: (HV) (DC) injury or death hazard, use at your own risk, may void warranty. |
Difference between revisions of "Prius PHEV Schematics"
(→Hybrid-Pack Method: Link out the PriusPlus page for more info, and notes on commonality of HV taps.) |
(→PFC Based: notice changes, spelling.) |
||
Line 35: | Line 35: | ||
====Manual Anderson Quick Mode Change.==== | ====Manual Anderson Quick Mode Change.==== | ||
+ | This was used for early testing before the relay box was designed and produced. | ||
''View with fixed-width fonts'' | ''View with fixed-width fonts'' | ||
'''Manual Anderson Quick Mode Change.''' | '''Manual Anderson Quick Mode Change.''' | ||
Line 55: | Line 56: | ||
--[[User:Rjf|Rjf]] 00:40, 26 May 2006 | --[[User:Rjf|Rjf]] 00:40, 26 May 2006 | ||
− | ====Automatic Charge - PHEV Drive Mode Change==== | + | ====Automatic Charge - PHEV Drive Mode Change (With Regen)==== |
− | ''View with fixed-width fonts'' <font color=red>'''This has not yet been validated for proper | + | ''View with fixed-width fonts'' |
+ | <font color=red>'''This has not yet been validated for proper operation, and may not have ever been implemented.'''</font> | ||
'''Automatic [ Charge - PHEV Drive - Regen ] Mode Change, HV Layout''' | '''Automatic [ Charge - PHEV Drive - Regen ] Mode Change, HV Layout''' | ||
Pair of DPDT or 4PDT, DPDT, and SPST (40+ Amps, 12v coils) | Pair of DPDT or 4PDT, DPDT, and SPST (40+ Amps, 12v coils) | ||
Line 91: | Line 93: | ||
--[[User:Rjf|Rjf]] 15:49, 14 June 2006 (CDT) | --[[User:Rjf|Rjf]] 15:49, 14 June 2006 (CDT) | ||
---- | ---- | ||
− | + | ''View with fixed-width fonts'' | |
− | '''coils''' '''''Can we get a four poll | + | <font color=red>'''This has not yet been validated for proper operation, and may not have ever been implemented.'''</font> |
+ | '''coils''' '''''Can we get a four poll triple throw 40A, 60A, or 120A Contactor or Drum Switch?''''' | ||
'''12345''' | '''12345''' | ||
----- '''Charge Mode''' | ----- '''Charge Mode''' | ||
Line 134: | Line 137: | ||
''11001 - '''coil 01''' & 02 states may be safe to combined'' | ''11001 - '''coil 01''' & 02 states may be safe to combined'' | ||
''Forced PbA Charge Mode'' | ''Forced PbA Charge Mode'' | ||
− | ''(One could manually enter forced PbA charge mode by safely | + | ''(One could manually enter forced PbA charge mode by safely engaging stationary regen '''?RL3^?)'' |
''Further, External Charging by:'' | ''Further, External Charging by:'' | ||
''(Shut off PFC, hyjack PFC output via Andersons, V tune (?independent?) and charge)'' | ''(Shut off PFC, hyjack PFC output via Andersons, V tune (?independent?) and charge)'' | ||
--[[User:Rjf|Rjf]] 15:49, 14 June 2006 (CDT) | --[[User:Rjf|Rjf]] 15:49, 14 June 2006 (CDT) | ||
---- | ---- | ||
− | ''View with fixed-width fonts'' <font color=red>'''This has not yet been validated for proper | + | ''View with fixed-width fonts'' |
+ | <font color=red>'''This has not yet been validated for proper operation, and may not have ever been implemented.'''</font> | ||
'''Automatic [ Charge - PHEV Drive - Regen ] Mode Change, LV Layout''' | '''Automatic [ Charge - PHEV Drive - Regen ] Mode Change, LV Layout''' | ||
(-)12v Acc(+) | (-)12v Acc(+) | ||
Line 176: | Line 180: | ||
| !DPDT CAN-RL5+6, (Regen) ! | | !DPDT CAN-RL5+6, (Regen) ! | ||
#==========!=NO======================!=Coil 03===(-) 12v | #==========!=NO======================!=Coil 03===(-) 12v | ||
− | ( Remove (-(1) 12v) Coil 04 Drops | + | ( Remove (-(1) 12v) Coil 04 Drops Immediately ) |
( Coil 01&02 Delayed ) | ( Coil 01&02 Delayed ) | ||
( Coil 03 Delayed More ) | ( Coil 03 Delayed More ) | ||
− | ( Adding (-(1) 12v) Coil 03 Drops | + | ( Adding (-(1) 12v) Coil 03 Drops Immediately ) |
( Coil 01&02 Delayed ) | ( Coil 01&02 Delayed ) | ||
( Coil 04 Delayed More ) | ( Coil 04 Delayed More ) | ||
Line 199: | Line 203: | ||
====Automatic Charge - PHEV Drive Mode Change (No Regen)==== | ====Automatic Charge - PHEV Drive Mode Change (No Regen)==== | ||
− | ''View with fixed-width fonts'' <font color=red>'''This has not yet been validated for proper | + | ''View with fixed-width fonts'' |
+ | <font color=red>'''This has not yet been validated for proper operation, and may not have ever been implemented.'''</font> | ||
'''Automatic [ Charge - PHEV Drive ] Mode Change, HV & LV Layout''' | '''Automatic [ Charge - PHEV Drive ] Mode Change, HV & LV Layout''' | ||
coil 01 is a pair of DPDT or a single 4PDT | coil 01 is a pair of DPDT or a single 4PDT |
Revision as of 01:50, 6 December 2008
This is where you will find schematics, PCB layout, and parts lists for various Prius PHEV conversions.
Original CalCars Method
Further development of the PriusPlus History or Prius PHEV#Original CalCars Method has been postponed to persue the Prius PHEV#Hybrid-Pack Method so the original schematics can be found at Prius PHEV Schematics-CalCars
Hybrid-Pack Method
There is no longer a need for the Battery Tap Emulator when using a hybrid battery pack configuration. The HV interface with the original OEM battery is made after the HAL (current) sensor. If the OEM BMS does not measure enough current leaving the OEM battery it will shut down the OEM HV systems within about 1 mile or a few minutes. The OEM BMS does not however appear to mind to much current leaving the OEM battery, thus it may be possible to draw large amounts of power out of the OEM battery through the HAL sensor for a sort of "Genset Mode" of operation. These HV taps between the OEM and add on PHEV Battery Pack are common between the Contactor and PFC based conversions.
View with fixed-width fonts |======[? (-) for Genset Mode ?] | =(-)=[=#=OEM_Contactor=#=]===[|]==#========(-) HAL | [_OEM_Battery_] To HSD SENSOR | |===(+) | | =(+)=[=#=OEM_Contactor=#=]========|====| | | |====| | | | ( # interconnect ) (+) (-) ( = & | 6 guage wire ) [_PHEV_Battery_]
Contactor Based
See the PriusPlus article for schematics, documentation, and other resources for the Contactor Based PriusPlus Mothod.
PFC Based
No new Schematics for these methods yet, Only ASCII Art...
Manual Anderson Quick Mode Change.
This was used for early testing before the relay box was designed and produced.
View with fixed-width fonts Manual Anderson Quick Mode Change. ( 6 red, 6 black ) _______________ _ _____________________ In PFC AC(+) \ / (+) 110/220AC CHG | _____PFC_AC(-)_/_\_(-)____________ CHG______ Out PFC DC(+) \ / (+) PbA (PHEV) CHG PHEV | _____PFC_DC(-)_/_\_(-)________________ PHEV_____ / (+) NiMH (OEM) PHEV RGN | _ _ _ _ _ _ _ _ _\_(-)____________ _ _ _____RGN | / (+) PbA (PHEV) RGN | _ _ _ _ _ _ _ _ _\_(-)____________ _ _ _ _ _____| _ ________________ "Special Mode" / (+) HSD (? HAL sensor ?) Wayland at the _\_(-)____________ track charging / (+) DC Output (! NEDRA !) Genset Mode ?? _\_(-)____________ --Rjf 00:40, 26 May 2006
Automatic Charge - PHEV Drive Mode Change (With Regen)
View with fixed-width fonts This has not yet been validated for proper operation, and may not have ever been implemented. Automatic [ Charge - PHEV Drive - Regen ] Mode Change, HV Layout Pair of DPDT or 4PDT, DPDT, and SPST (40+ Amps, 12v coils) (+)[Grid](-) Inputs --> State|Machine --> Outputs __|________|__ +12v-|->(CAN RL3, NO, RGN )-->|-->(Execute Regen mode Procedure below) ! |coil 05 | ! Key |->(CAN RL2, NO, SOC )-->|-->(PFV V set NiMH high) ! |AC rated| ! |->(CAN RL4, NO, PHEV)-->|-->(coil 04) !_|________|_! |-NC->(Key On, +12v, Brown)-->|-->(Interlock, coil 01 & 02, PFC V set NiMH low) | | | |-NC----------->|-->(Open OEM HV+ Contactor ground control, Black) (|AC sense|)---|-------------|----110vac---->|-->(PFC Current <15Amps) | | | |====|======================================| | | | | | | | |==================================|========| __|___|____|___|__ | | ! # # # # ! | | ! \ , %%%% \ , ! | | ! \ coil \ ! (+)[PbA](-) (-)[NiMH](+)[NiMH](-)Regen Mode? !___#___03___#___! | | | | Inverter side of OEM contactor | | | | | | | |====|========#=======|==========|====| | | | | | | | | | | | |=======| #======| | | | | | | | __|____|__ | | | | | | | | | # ,, # ! | | | | __|___|____|___|__ ! ---- ! __|___|____|___|__ ! # # # # ! ! %%%% ! ! # # # # ! ! \ , %%%% \ , ! ! coil ! ! \ , %%%% \ , ! ! \ coil \ ! !___04___! ! \ coil \ ! !___#___01___#___! !___#___02___#___! | | | | |(+) (-)| |(-) (+)| [PFC Input] [PFC Output] --Rjf 15:49, 14 June 2006 (CDT)
View with fixed-width fonts This has not yet been validated for proper operation, and may not have ever been implemented. coils Can we get a four poll triple throw 40A, 60A, or 120A Contactor or Drum Switch? 12345 ----- Charge Mode 00000 - Grid -> PbA, (PFC V set PbA default) ////0 - 110v AC Present (DC immune) coil 01-04, Key On, and RLx interlock. (Set PFC Current < 15A) ////0 - 220v AC Present (DC immune) coil 01-04, Key On, and RLx interlock. (Leave PFC Current Full) - Key On Interlock opens a NC relay which grounds the (+)pos OEM Contactor. - Run Interlock opens a NC relay which would otherwise go (+12) upon Key On. - Open a NC relay which provides coil 01-04 & CAN RLx grounds, disabling all. ----- Power up sequence Key On 00000 - Key Off, ready to but not charging state 00001 - open coil 05 (NC), ac interlock 01001 - coil 02 Output -> NiMH, PFC V set NiMH low 11001 - coil 01 Input -> PbA CAN-View "PHEV" Mode, Relay RL4^ 11011 - Close coil 04 (NO), Connect PbA (-)neg leg (PFC On) CAN-View ?RL2^? (SOC/CCL Driven) 11011 - PFC V set NiMH high ----- Power down sequence Key Off 11011 - Key On, and PHEV run state 11001 - Open coil 04 (NO), Disconnect PbA (-)neg leg (PFC Off) 01001 - coil 01 Input -> Grid 00001 - coil 02 Output -> PbA, PFC V Set PbA 00000 - close coil 05 (NC), ac interlock ----- CAN-View ?RL3^? (Enter Regen Mode) 1 - only while grid interlock is active 11011 - Key On, and PHEV run state Do Power down sequence Emulate Key Off less last state 11001 - Open coil 04 (NO), Disconnect PbA (-)neg leg (PFC Off) 01001 - coil 01 Input -> Grid 00001 - coil 02 Output -> PbA, PFC V Set PbA 00101 - coil 03 NiMH(Regen) -> Grid Input (PFC On) ----- CAN-View ?RL3v? (Exit Regen Mode) 00101 - Key On, and PHEV regen state 00001 - coil 03 Grid -> Grid Input (PFC Off) 01001 - coil 02 Output -> NiMH, PFC V Set NiMH low 11001 - coil 01 Input -> PbA 11011 - Close coil 04 (NO), Connect PbA (-)neg leg (PFC On) ----- Other Notes 01001 - coil 02 & 01 states may be safe to combined 11001 - coil 01 & 02 states may be safe to combined Forced PbA Charge Mode (One could manually enter forced PbA charge mode by safely engaging stationary regen ?RL3^?) Further, External Charging by: (Shut off PFC, hyjack PFC output via Andersons, V tune (?independent?) and charge) --Rjf 15:49, 14 June 2006 (CDT)
View with fixed-width fonts This has not yet been validated for proper operation, and may not have ever been implemented. Automatic [ Charge - PHEV Drive - Regen ] Mode Change, LV Layout (-)12v Acc(+) | | |======# |========| | ____|____ ____|____ | ! # ! ! # ! (-)12v | ! \ ! ! \ ! (+)12v When======#===#%,%\%#===| |====#%,%\%#=======(Brown) AC Exists !_#___#_! | | !_#___#_! Key On | | | | | | MM-PFC=========| #====|===| | | LowCurrent | | | | if 110vac | |=========|===| | | OEM (-) Contactor | | Leg (Black)========| | AC/Run Interlocks ...................................|..................... (+) |=========================| | | SPDT #===NO==(Coil 01 & Coil 02), MM-PFC Vset Ni-Low=======(-(1) 12v)===# | (Cap to Delay Opening and Closing) | | | | SPDT | #===NO==CAN-RL4, Coil 04 (Pb->MM-PFC, Power On)=======(-(1) 12v)===# | (No Cap, Opens and Closes Instantly) | | | | SPDT | #===NO==CAN-RL2+3, (SOC Driver) MM-PFC Vset Ni-High===(-(1) 12v)===# | | | | | | | (-) 12v=!=NC======================!=============>==(-(1) 12v)=>=# | !DPDT CAN-RL5+6, (Regen) ! #==========!=NO======================!=Coil 03===(-) 12v ( Remove (-(1) 12v) Coil 04 Drops Immediately ) ( Coil 01&02 Delayed ) ( Coil 03 Delayed More ) ( Adding (-(1) 12v) Coil 03 Drops Immediately ) ( Coil 01&02 Delayed ) ( Coil 04 Delayed More ) --Rjf 00:24, 22 June 2006 (CDT)
Enhanced Regen
Regen may need to transfer power through the OEM HAL sensor in order to:
- Avoid Negative State Of Charge Drift which may not work like +Drift.
- Allow current to be counted instantaneously and thus recover from or avoid CCL.
- Allow for the use of the Prius as a DC Genset if PFC sources NiMH pack.
Potential Enhanced Regen methods
- Use the PFC as is, switch Input/Output and change voltage setpoint.
- Modify the PFC so it can move 2x amps in DC modes only.
- Use a PFC power stage.. so we can stuff 150 amps in any direction.
- Use a Honking Big diode and a properly sized PbA Pack.
- Use a contactor and a diode and a properly sized PbA Pack.
Automatic Charge - PHEV Drive Mode Change (No Regen)
View with fixed-width fonts This has not yet been validated for proper operation, and may not have ever been implemented. Automatic [ Charge - PHEV Drive ] Mode Change, HV & LV Layout coil 01 is a pair of DPDT or a single 4PDT coil 02 is a SPST (Rated 40+ Amps for DC MAKE/BREAK) * Ignition energizes mode change (unless PFC is running from grid) * CAN-View RL4 (OEM/PHEV Mode) energizes Coil 02 powering up PFC (DC MAKE) * Once PFC is running mode change is energized by both ignition and PFC RegBus ** Ignition off results in CAN-View RL4 releasing powering down PFC (DC BREAK) ** Mode change can only return to grid once PFC RegBus goes offline (+)[Grid](-) (+)[PbA](-) (-)[NiMH](+) | | | | | | | |====|========#=======|==========|====| | | | | | | | | | | | |=======| #======| | | | | | | | __|____|__ | | | | | | | | | # ,, # ! | | | | __|___|____|___|__ ! ---- ! __|___|____|___|__ ! # # # # ! ! %%%% ! ! # # # # ! ! \ , %%%% \ , ! ! coil ! ! \ , %%%% \ , ! ! \ coil \ ! !___02___! ! \ coil \ ! !___#___01___#___! !___#___01___#___! | | \ / | | |(+) (-)| \ / |(-) (+)| ( +5v from ) [PFC Input] \ / [PFC Output] ( PFC RegBus ) \<===#===>/ | | | | | (Ign +12v)---< |=====| |=====#==========|====================| | | | | __|____|__ | | | | | | | | # ,, # ! | (coil / 01) |========| | | | | |=====| | ! ---- ! | ______|________|__ __|____|__ | | __|____|__ | | g===%%%%====| | ! # # # # ! | # ,, # ! | | | #____# ! | | ! NO ! | |====%\ ,%%%%%%\ ,%==g ! ---- ! | | ! .... ! | | !________! | ! \ \ ! |====%%%%=====#=|=====%%%%====| | | | !___#________#___! | ! NO ! | ! NC ! | | | | | | | !________! | !________! | | |===(Bat +12)==|========#========# |===============#=============| | | | | ^ |========================================================| --Rjf 06:51, 2 September 2006 (CDT)